Vacuum or Pressure closures for small/portable ASME vessels
Many processors come to Apache for a vessel solution in the incubation stage of their business. In some cases, they are looking for help to choose the right kind of vessel that will suit their needs and fit their budget. While Apache provides custom ASME vessels for a range of industries, we also offer a line of standard vessels that often solve what these manufacturers need for their process.
The use of the vessel will determine whether it is a pressurized solution, non—pressurized or vacuum vessel solution.
Vessels that require a minimum of 50 PSI, utilize a pressure closure. Numerous applications, including heating or cooling process, containment, and pressurized dispensing often utilize pressures at or above 50 psi.
It is important to note the safety and ASME requirements for pressure vessels, an ASME UM-mark is required for:
For vacuum requirements or non-vacuum applications, such as a storage vessel or collecting vessel, a vacuum closure may suit the application.
In the video, Nick Buchda, Apache’s Small Vessel Representative, demonstrates vacuum and pressure closures on our standard line of vessels.
Apache has produced stainless vessels with ASME certification for over 45 years, with other accreditations for pharmaceutical, life science and health industries including ASME UM, ASME U, FDA, 3-A, CRN, PED and BPE.
Whether the vessel needs fit a standard vessel, modifications to a standard vessel or a custom solution, Apache has the experience to fulfill a range of critical, sanitary-design vessel solutions.
ASME is a leading developer of codes and standards in the mechanical engineering community. These standards enhance public safety and health as well as promote innovation.
The ASME (American Society of Mechanical Engineers) mark is a single certification marketing to signify the international mark of safety and quality. Recognized worldwide, manufacturers that provide ASME have a rigorous quality program, and a third-party review to authorize the use of the mark.
The U mark certifies that the pressured tanks or vessel conforms to the latest edition of the ASME code and that the pressure vessel has been designed and manufactured in accordance with ASME. All aspects are approved by a Third party ASME Authorized Inspector (AAI). U stamps require an ASME inspector to witness the ASME hydro test.
Companies with a U mark undergo a review with the National Board every three years.
The UM mark certified that the pressure vessel or tank conforms to the latest edition of the ASME code and that the pressure vessel has been designed and manufactured in accordance with ASME. The UM vessel’s designation is related to the size of the tank/vessel.
While the American Society of Mechanical Engineers writes the rules for the new construction of pressure vessels and tank, the National Board of Boiler and Pressure Vessel Inspectors write the inspection code for new and repaired vessels.
The National Board of Boiler and Pressure Vessel Inspectors require a Certificate of Authorization and R stamp for the repair or alteration of boilers, pressure vessels and other pressure retaining equipment.
Apache has been ASME certified for over 45 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.
Custom vessel manufacturing to industries requiring compliance is what we do. There is a process for customer service and engineering that is required to get the custom vessel you require for your application. There are numerous specifications that will be required based on your process or level of compliance. Apache will work with you to explain and provide options in your vessel project. This collaborative effort will have to control cost and expedite timing for your custom vessel.
Here are our 12 Project Engineering Steps to Ensure Vessel Compliance:
Apache’s engineering team articulates technical discussions and is open with timelines, cost and compliance-related issues. Our competence for a pharmaceutical or life science industry vessel is strongly supported in providing all compliance related deliverables.
The particular RA (Roughness Average) value is a requirement for stainless vessel manufacturing for federal, state or local compliance agencies across many critical industries. It is a crucial standard in these industries to maintain a clean system. The instrument used in the measurement is called a profilometer, which provides an average in micro inches. The smaller the number, the smoother the stainless material. It is common for high compliance vessels to have single digit RA readings on product contact surfaces.
In the construction of pharmaceutical, life sciences, or medical-use vessels, meeting the RA requirement may include several steps, including material selection, grinding, polishing and chemical finishing. Manufacturing processes can affect the RA measurement on stainless material, including forming, stamping and welding. In the video, we walk out of the manufacturing plant with our quality controls manager to show measurements on material in vessels being manufactured in various stages of production.
Pickle Passivation and Electropolishing chemical finishes have a high degree of improvement on RA smoothness compared to material before it is treated. Pickle passivation, also referred to as descaling, removes the scales and leaves a clean matte finish, free from contamination. Electropolishing is an electrochemical process that dissolves surface metal, removing all embedded contaminants and creates a smooth, mirror finish.
ASTM International (American Standard for Testing and Materials) is one of several standards that Apache upholds. ASTM A967 is the standard specification for Chemical Passivation Treatment for Stainless Parts. ASTM B912 is the standard specification for electropolishing stainless steel alloys. The ASME-Bioprocessing Equipment (BPE) standard was created for the pharmaceutical and bioprocessing industry. The BPE surface finish standard classifies surface finishes and the acceptance criteria for compliance.
In the business of compliance vessels, there are numerous standards that are required to deliver the necessary codes in any given project. Follow our videos, blogs and e-books developed specifically to help our processing customers understand the manufacturing and compliance process.
Processors serving food or hygienic industries have varying degrees of compliance requirements for custom vessels solutions. The designation of "sanitary" has a wide range of definitions depending on the customer, the industry or the standard.
This video is a brief overview how Apache defines a base, mid, and high-level sanitary vessels.
Apache Stainless Equipment Corporation is a manufacturer of stainless equipment for a range of hygienic industries, including, food, beverage, biotechnology, pharmaceutical, cannabinoid, and life sciences.
A dedicated quality control and compliance team directs all tests, certificates and documents for all sanitary, ASME, and global standards.
ASME (American Society of Mechanical Engineers) is a leading developer of codes and standards in the mechanical engineering community. ASME code section VIII details mandatory rules regarding vessel design, including engineering, manufacturing, and testing of pressure vessels. These standards enhance public safety and health as well as promote quality and innovation. Here are the main parameters outlining ASME construction of pressure vessels with supporting ASME testing requirements.
Construction Parameters such as wall thickness, material, and flange rating are determined by the application, including pressure, temperature, corrosion allowance, and fluid flow. These conditions are calculated and reviewed/approved by the ASME inspector when required per code. Stainless, Hastelloy, AL6XN, duplex, and Inconel materials are ASME-approved materials for pressure vessel construction in the pharmaceutical, life sciences, and health-related industries, of which Apache is qualified to fabricate. Welding ASME standards also define the quality, type, and finishing of the welds. Head styles (ASME F&D, 80:10, 2:1 Elliptical), seams, nozzles, manways, and other components are designed per ASME Code. Applicable ASME Code welding procedures must be followed using certified ASME welders to maintain the structural integrity of an ASME pressure vessel. Welders must be certified to a qualified weld specification qualified per ASME code guidelines. Safety Components Gauges, valves, pressure outlets, and drainage are required safety components in ASME design pressure vessels. The proper selection of components and design is critically important to the safety and performance of the ASME vessel. The selection of safety components needs to be evaluated closely to define the required scope of supply. Finishing There is another ASME specification to ensure the quality and safety of parts used in pharmaceutical, bio-processing, and other industries requiring a hygienic vessel, called ASMP-BPE. BPE (Bio Processing Equipment Standard) specifies the surface finishes RA (roughness average) requirements and pickle passivation and electropolishing requirements. Tests & Certification There are significant testing, certifications, and documentation requirements for ASME compliance and satisfying the numerous customer requirements. Many require ASME inspection as well as a TOP (turnover packet). Some ASME testing and certification requirements include pneumatic, hydrostatic, liquid penetrant, saline, riboflavin, CIP coverage, material, base metal thickness, material trace, welder trace, Ferroxyl, PMI (Positive Material Identification) radiography, and UT. Apache has been ASME certified for over 40 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.
As the Cannabis Processing industry continues to evolve, increasing regulations are following. With continuous new products and additive combinations entering the market, the sale and distribution of the products will have more regulations. The processing and production of CBD and cannabidiol components are already seeing increasing standards.
When searching for a new Cannabis Processing or Extraction vessel equipment supplier, ask these five questions:
Apache Stainless is a manufacturer of sanitary, highly engineered, ASME pressure vessels for a multitude of industries, including cannabis processing, pharmaceutical, health and biopharma. We have served the Cannabis and CBD processing industry several years with processing tanks, hydrocarbon extraction tanks, mixing tanks and separating vessels. We also design and manufacture vessels with Canadian Registration Numbers (CRN) for all Canadian provinces. We have all Stainless ASME certified manufacturing facility with custom capabilities including heat exchange surfaces, agitation, CIP (clean-in-place) componentry and controls. Apache has an in-house quality and compliance team to provide all testing and documentation requirements.
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Accreditations
Custom and pressure vessel manufacturers must have accreditation for ASME certification. Compliance with the National Board of Boiler and Pressure Vessel code is required. Pressure vessel manufacturers must also manufacture to ASME material specifications, certificates, and welding qualifications.
Other accreditations are also crucial in the pharmaceutical, life science, and health industries. Confirm all industry compliance standards, including: • ASME UM • ASME U • FDA • 3-A • CRN • PED • BPE
Quality Assurance & Compliance
Verify that the manufacturer has a dedicated quality assurance team. There are significant testing, certifications, and documentation requirements for all global accreditation programs. In-house inspection services are a benefit to ASME projects. Review services that should include: • Pneumatic testing • Hydrostatic testing • Liquid Penetrant (Dye Penetrant) testing • Saline testing and certificate • Riboflavin/CIP (clean-in-place) coverage test • Material Test Reports • Base metal thickness certificate • Material trace • Welder trace • Ferroxyl test and certificate • Positive material identification (PMI) and certificate • Ferrite levels and certificate • Radiography and analysis • UT weld testing and certificate • Turn Over Packet (TOP) as required
Experience
The pressure vessel manufacturer must have expertise in the type of vessel and industry experience for the use of the vessel. Critical staff, fabricators, and welders must be ASME certified. All welders must be approved for the weld procedures required to make custom pressure vessels.
Experience and reputation are also significant when developing relationships with inspectors, agencies, and governing officials to keep the compliance process moving forward smoothly.
Service & Support
Above all, assess the service and support provided by the manufacturer. The vessel manufacturer should be able to articulate technical discussions and be open and honest with timelines, cost, and compliance-related issues. Consider other research and questions, such as:
• Is the proposal easy to understand and compare solutions? • Do you have direct access to the engineer for questions? • Does the company provide timely and accurate documentation? • Does the company offer after-market parts and field service?
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There are several reasons why a vessel may need service, however, two main causes why a vessel may need service are either accident or performance related.
In the case of an accident, such as a tool falling into the tank and causing damage; surface scratches and dents can typically be repaired on-site, provided they do not go beyond minimum requirements, with mechanical polishing or hand/wand electropolishing.
Reduced agitator performance or failure is often due to worn parts, improper assembly or a bent or broken shaft. Agitator repairs may be addressed with the agitator manufacturer or the vessel manufacturer, depending on the situation, down-time, and severity of the failure.
When troubleshooting a drop in pressure in a tank or vessel, a typical cause is often related to seals. One sign of seal failure is product coming out of the seal. To help reduce the frequency of an unexpected seal leak occurring, it is recommended to use a good seal maintenance program to solve a lot of pressure / performance issues, such as: • Seal replacement has been neglected • Flat spots on seals are a sign for replacement • Improper or incorrect seals for the outlet • Nicks, scratches or mishandling of seals
A best practice is to avoid product waste and critical down-time is to inventory seals for all outlets and manage seals in a preventative maintenance program.
It is important to note that any weld repairs to the ASME pressures zones on tanks, require an R-Stamp. The R-Stamp is a certification required by the National Board of Boiler and Pressure Vessels for repair of an ASME tank or vessel.
Depending on the size of the vessel and type of repair, Apache’s service techs may be able to make repairs on site or in some cases, tanks are shipped back to the factory. Apache can provide services including: • Field service and troubleshooting to all types of stainless and high alloy tanks • ASME / National Board R-Stamp repair and modifications • Surface finish repairs • Non-code repairs and modifications including piping and heat transfer jackets • Seal and agitation repairs and modifications • Accessory repairs • Head and tank shell repairs • Leak detection • Audit and service contract available
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Emerging life sciences, and health and wellness product manufacturers must carefully plan budget and start-up costs to launch their products. Many of these entrepreneurs begin production with a general use vessel.
A stainless general use vessel has a lower entry price. Depending on the process and the demand for the product, general-use vessels may serve a small manufacturer very well for many years. Dispensing and storage vessels, vacuum, and low-pressure vessels are common examples of general use applications.
However, when demand outpaces production, the manufacturer may require a vessel that is customized for the processing needs. Here is a case story of a manufacturer that switched from a general use to a custom ASME pressure vessel:
BEFORE: A fast-growing botanical extraction processor was unable to produce the quantity of product needed to fulfill demand. Their process involved an imported general use vessel that was placed in a rudimentary ice bath for temperature control. This process resulted in waste of non-consistent product, constant staffing, and manual intervention to monitor and adjust.
AFTER: Apache's small vessel team provided an ASME processing vessel that completely replaced their batch process. The new vessel was designed with a thermal heat jacket that heated and cooled the product to the exact temperature required for the extraction process. The ASME vessel was jacketed with tri-clamp ferrules and included a site glass and high-pressure sanitary fittings. The vessel has a pickle passivated finish that provides ease of sanitation between batches.
While the price point for a custom manufactured vessel was higher than a general use tank, the ability to quadruple production off-set the cost of the vessel and resulted in a quick return on investment. Apache's custom vessel runs continuously day and night; it eliminated product waste and removed employee monitoring and intervention.
Visit standard vessels or visit custom ASME vessels for more information!
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